Graco Inc 311001C User Manual

Instructions - Parts List

AA Series Spray Gun

For air-assisted spraying and finishing of paints and coatings.

Important Safety Instructions:

Read all warnings and instructions in this manual. Save these instructions.

See page 2 for List of Models and Table of Contents.

311001C

Model G15

Model G40

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441

TI6844A

TI6553A

Model G40 w/RAC tip

II 2 G

TI7204B

Contents

Models

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flush Before Using Equipment . . . . . . . . . . . . . . 8

Select a Spray Tip and Air Cap . . . . . . . . . . . . . . 8

Install a Spray Tip . . . . . . . . . . . . . . . . . . . . . . . . 8

Position the Air Cap . . . . . . . . . . . . . . . . . . . . . . 8

Air Cap Alignment Pin . . . . . . . . . . . . . . . . . . . . . 8

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pressure Relief Procedure . . . . . . . . . . . . . . . . 10

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

How the Air-Assisted Spray Gun Operates . . . . 11

Spray Pattern Adjustment . . . . . . . . . . . . . . . . . 11

HVLP Operation . . . . . . . . . . . . . . . . . . . . . . . . 12

Fluid Application . . . . . . . . . . . . . . . . . . . . . . . . 12

Daily Gun Care, Flushing, and Cleaning . . . . . . . 13

General System Maintenance . . . . . . . . . . . . . . 14

Fluid Filter Maintenance . . . . . . . . . . . . . . . . . . 14

Flushing and Cleaning . . . . . . . . . . . . . . . . . . . 14

Reverse-A-Clean

(RAC) Tip . . . . . . . . . . . . . . 16

Clearing a clogged RAC tip . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

General Troubleshooting . . . . . . . . . . . . . . . . . . 18

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Items Needed for Service . . . . . . . . . . . . . . . . . 20

Repair Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fan Valve Replacement . . . . . . . . . . . . . . . . . . . 20

Complete Gun Packing Repair . . . . . . . . . . . . . 20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 20

Seat Repair . . . . . . . . . . . . . . . . . . . . . . 20

Needle Repair . . . . . . . . . . . . . . . . . . . . 21

Air Valve Repair . . . . . . . . . . . . . . . . . . 22

Fluid Tube Replacement . . . . . . . . . . . 22

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 24

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spray Tip Selection Chart . . . . . . . . . . . . . . . . . . . 30

AAM Fine Finish Spray Tips . . . . . . . . . 30

GG4 Industrial Spray Tips . . . . . . . . . . 30

LTX RAC Spray Tips . . . . . . . . . . . . . . 31

FFT Fine Finish RAC Spray Tips . . . . . 32

WRX WideRAC Spray Tips . . . . . . . . . 32

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 36

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 36

Models

Maximum

Working Air

Part

No. Series

249233 B 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure

287926 A 100 (0.7, 7.0) 1500 (10.5, 105) G15 Medium Pressure

249242 B 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted

249246 A 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure, High Flow

249238 A 100 (0.7, 7.0) 4000 (2.8, 280) G40 High Pressure Air-Assisted

Pressure

psi (MPa, bar)

Maximum

Working Fluid

Pressure

psi (MPa, bar) Description Includes:

Air-Assisted Spray Gun, Plastic Seat, SST Ball

Air-Assisted Spray Gun, Carbide Seat and Ball

Spray Gun, Carbide Seat and Ball

Air-Assisted Spray Gun, Carbide Seat and Ball

Spray Gun, Carbide Seat and Ball, Reverse-A-Clean

(RAC) Tip

249596 Air Cap

249180 Air Cap

249478

RAC

Air Cap

2 311001C

Related Manuals

This manual is available in the following languages:

Manual Language

311001 English

311145 Chinese

311146 Danish

311147 Dutch

311148 Finnish

311149 French

311150 German

311151 Italian

311152 Japanese

311153 Korean

311154 Norwegian

311155 Polish

311156 Russian

311157 Spanish

311158 Swedish

Related Manuals

311001C 3

Warnings

The following are general warnings related to the setup, use, grounding, maintenance, and repair of this equipment. Additional, more specific warnings may be found throughout the body of this manual where applicable. Symbols that appear in the body of the manual refer to these general warnings. When these symbols appear throughout the manual, refer back to these pages for a description of the specific hazard.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only.

• Do not alter or modify equipment.

• For professional use only.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or overbend hoses or use hoses to pull equipment.

• Comply with all applicable safety regulations.

• Keep children and animals away from work area.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

4 311001C

Warnings

WARNING

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

311001C 5

Installation

Typical Installation

The typical installation shown in FIG. 1 is only a guide for selecting and installing air-assisted spray systems. Contact your Graco distributor for assistance in designing a system to meet your needs.

VENTILATE THE SPRAY BOOTH

To prevent hazardous concentrations of toxic and/or flammable vapors, spray only in a properly ventilated spray booth. Do not operate the spray gun unless ventilation fans are operating.

Check and follow all of the National, State, and Local codes regarding air exhaust velocity requirements.

Check and follow all local safety and fire codes.

Grounding

Check your local electrical code and pump manual for detailed grounding instructions. Use only electrically conductive fluid hoses.

Ground the spray gun through connection to a properly grounded fluid supply hose and pump.

FIG. 1: Typical Installation (Model G15 Shown)

Key:

A Air Line Filter B Air Shutoff Valve C Gun Air Pressure Regulator DAir Line

TI6554A

ESpray Gun F Electrically Conductive Fluid Hose G Gun Air Supply Hose

6 311001C

Installation

Air Line

1. Install an air filter (A) on the gun air line to ensure a dry, clean air supply to the gun. Dirt and moisture can ruin the appearance of your finished workpiece. See F

IG. 1.

2. Install an air pressure regulator (C) on the gun air line to control air pressure to the gun.

3. Install an air shutoff valve (B) on the gun air line and on the pump air line, to shut off air to the gun.

4. Use a 3/16 in. (5 mm) I.D. or larger air hose to minimize excessive pressure drop in the hose.

The gun air inlet has a 1/4-18 npsm (R1/4-19) compound male thread that is compatible with NPSM and BSP female swivel connectors.

5. Connect the air hose (G) to the 1/4 npsm gun air inlet. See F

IG. 2.

Fluid Line

• Before connecting the fluid line, blow it out with air and flush it with solvent. Use solvent which is compatible with the fluid to be sprayed.

• If better control of fluid pressure is needed, install a fluid regulator on the fluid line to better control fluid pressure to the gun.

1. Use a fluid filter to remove coarse particles and sediment, to avoid clogging the spray tip and causing finishing defects.

Guns are equipped with a built-in 100 mesh fluid filter to provide final filtering just before spraying.

2. Connect the fluid hose (F) to the gun fluid inlet. See F

IG. 4. If desired, install a fluid swivel connector

(115898) at the gun inlet for best maneuverability. See Accessories, page 33.

TI6556A

IG. 2

6. Connect the other end of the air hose (G) to the outlet of the air shutoff valve. See F

IG. 3.

TI4838A

IG. 3

TI6846A

IG. 4

3. Connect the other end of the fluid hose (F) to the pump fluid outlet.

311001C 7

Setup

Flush Before Using Equipment

1. The equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flushing and Cleaning, page 14.

2. Relieve the pressure. See Pressure Relief Proce- dure, page 10.

Setup

Select a Spray Tip and Air Cap

The fluid flow and pattern width depend on the size of the spray tip, the fluid viscosity, and the fluid pressure. See Spray Tip Selection Chart, page 30. Contact your Graco distributor for assistance in selecting an appropriate spray tip for your application.

Install a Spray Tip

Install a spray tip in the gun. Ensure that the tip locating tab is positioned in the slot of the air cap. See F Tighten the air cap retaining ring (6) firmly by hand to ensure a good seal between the tip gasket and the diffuser (5).

IG. 5.

TI6558A

IG. 6

Air Cap Alignment Pin

Model G15 guns (249233) use an air cap alignment pin to position the air cap. The standard location of the air cap alignment pin is the horizontal air cap position.

If you would like to change the spray pattern direction, use a needle nose pliers to unscrew the pin and relocate it to the desired position. See F the pin use low-strength thread locker. Torque to 1.5-2.5 in-lb (0.2-0.3 N•m). DO NOT OVERTIGHTEN.

The air cap alignment pin can be removed according to preference.

Air cap alignment pins do not come standard with model G40 guns (249242).

IG. 7. When relocating

Slot

Tip Locating Tab

IG. 5

Position the Air Cap

The air cap and spray tip position determines the direction of the spray pattern.

Rotate the air cap (the spray tip rotates with it) as needed to achieve the desired spray pattern direction. See F

IG. 6.

8 311001C

TI6847A

Horizontal

Air Cap Position

(standard)

Ver t i cal

Air Cap Position

IG. 7

TI6847A

Reverse-A-Clean® (RAC) Tip

Setup

Model 249238 guns use a Reverse-A-Clean® (RAC) tip.

To assemble the RAC tip, insert the seat housing into the air cap assembly.

TI7196A

IG. 8

Insert the SwitchTip.

TI7197A

IG. 9

Insert the gasket seat.

TI7198A

FIG. 10

Screw the RAC tip assembly onto the gun and tighten firmly by hand.

TI7199A

IG. 11

311001C 9

Operation

Safety

SKIN INJECTION HAZARD

Remember, this is not an air spray gun. For your safety be sure to read and follow the Warnings on pages 4 and 5 and throughout the text of this instruction manual.

Keep the wallet sized warning card (222385), provided with the gun, with the operator of this equipment at all times. The card contains important treatment information should an injection injury occur. Additional cards are available at no charge from Graco.

Pressure Relief Procedure

5. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure. See F

IG. 12.

TI6555A

FIG. 12

6. Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valve(s) open until you are ready to spray again.

7. Engage the trigger lock. See F

IG. 13.

SKIN INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure,

• stop spraying,

• check or service any of the system equipment,

• or install or clean the spray tip.

Follow Pressure Relief Procedure on page 10 when you stop spraying and before cleaning, checking, servicing, or transporting equipment. Read Warnings, page 4.

1. Engage the trigger lock. See FIG. 13.

2. Shut off the pump. See your pump manual.

3. Shut off the gun air supply.

4. Disengage the trigger lock. See F

IG. 13.

8. If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen the tip guard retaining ring or hose end coupling to relieve pressure gradually, then loosen completely. Clear hose or tip obstruction.

Trigger Lock

Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally by hand or if dropped or bumped.

IG. 13

ENGAGED

TI6581A TI6582A

DISENGAGED

10 311001C

Operation

How the Air-Assisted Spray Gun Operates

The air-assisted spray gun combines airless and air spraying concepts. The spray tip shapes the fluid into a fan pattern, as does a conventional airless spray tip. Air from the air cap further atomizes the fluid and completes the atomization of the paint tails into the pattern to produce a more uniform pattern. The width of the pattern can be adjusted by the pattern adjustment valve.

The air-assisted spray gun differs from an air spray gun in that increasing the pattern air reduces the pattern width. To increase the pattern width, use less pattern air or a larger size tip.

The spray gun has a built-in lead and lag operation. When triggered, the gun begins emitting air before the fluid is discharged. When the trigger is released, the fluid stops before the air flow stops. This helps assure the spray is atomized and prevents fluid buildup on the air cap.

2. Trigger the gun to check the atomization; do not be concerned about the pattern shape yet.

3. Slowly increase the fluid pressure, just to the point where a further increase in fluid pressure does not significantly improve fluid atomization.

4. Close off the pattern adjustment air by turning the knob clockwise (in) all the way. See F

sets the gun for its widest pattern.

OPEN

FIG. 14

IG. 14. This

TI6559A

Spray Pattern Adjustment

SKIN INJECTION HAZARD

To reduce the risk of component rupture and serious injury, including injection, do not exceed the gun’s maximum fluid working pressure or the maximum working pressure of the lowest rated component in the system.

1. Do not turn on the gun air supply yet. Set the fluid pressure at a low starting pressure. If a fluid pressure regulator is installed, use it to make adjustments.

If your system does not have a fluid regulator, the fluid pressure is controlled by the air regulator supplying the pump, per the formula below:

Pump Ratio

x Pump Air Regulator Setting = Fluid

Pressure

5. Set the atomizing air pressure at about 5 psi (0.35 bar, 35 kPa) when triggered. Check the spray pattern, then slowly increase the air pressure until the tails are completely atomized and pulled into the spray pattern. See F (0.7 MPa, 7 bar) air pressure to the gun.

For a narrower pattern, turn the pattern adjustment valve knob counterclockwise (out). See F the pattern is still not narrow enough, increase the air pressure to the gun slightly or use a different size

tip. (Not available for RAC tip guns.)

no air

IG. 15. Do not exceed 100 psi

IG. 14. If

TI0792A

too little air correct amount

of air

IG. 15

311001C 11

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